Insertion - Dukane iq series User Manual

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Problem
The insert pulls out easily in use.
Probable Cause
There is insufficient interference between
the hole and the insert.
The screw bottoms out in the hole.
The insert gets pushed into the plastic
before the plastic melts.
The ultrasound remains on after insertion
is complete.
The horn retracts before the plastic
around the insert is solidified.
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Problem
Inconsistent insertion of multiple inserts on the same part.
Probable Cause
The plastic is not melting consistently
around all inserts.
Inserts are pushed into the plastic
before the plastic has melted.
Inserts are seated at different heights
within the same part.
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Dukane Manual Part No. 403-586-02

Insertion

Solution
Reduce the size of the molded hole in
the plastic.
Use a shorter screw. (Applies to internally-
threaded insert).
Deepen the hole.
Use hydraulic speed control.
Increase the horn amplitude and/or decrease the air
pressure.
Use pre-triggering.
Decrease the primary weld characteristic.
Increase the hold time.
Solution
Increase the horn amplitude.
Use hydraulic speed control.
Reduce the down speed.
Use pre-triggering.
Evaluate the support provided by the
fixture. If required, re-level or shim the
fixture.
Measure the horn tip length to check for dimensional
consistency. If a varying length is found, send the
horn to Dukane for modification.
Section 9 - Troubleshooting
Continued
Page 125